Air freshener

ABSTRACT

An air freshener removably engages with a structure, such as the supporting post of a rear view mirror of a motor vehicle. The air freshener has a rigidifying core defining a central axis, and an outer portion or sleeve contacting the core that is formed from one or more fragrance loaded polymers. Together, the core and outer portion are shaped to surround a first axis perpendicular to the central axis. The ends of the air freshener are juxtaposed generally opposite one another in closed configuration, and the arm portions of the air freshener flex in directions substantially parallel to the first axis to separate the ends to open the air freshener. A breakable strap and/or connectors may be provided to join the ends together. Alternatively, one end of the air freshener may be inserted within a cavity formed in the opposite end of the air freshener.

FIELD OF THE INVENTION

The present invention relates to an air freshener formed of one or morepolymer resin(s) and having at least one portion or sleeve loaded with afragrance oil or oils or other fragrance material. The air freshener maybe formed as a clip with a strengthening core onto which the outerportion may be over molded. Opposing ends of the air freshener arejuxtaposed adjacent to one another when the air freshener is in closedposition. The opposing ends of the air freshener may be urged apart orflexed apart to open the air freshener for installation over or around areceiving structure. The air freshener is adapted to be hung aroundrods, handles or arms, such as, but not limited to, the neck or shoulderof an automotive rear view mirror, to be suspended therefrom and releasefragrance into the air.

BACKGROUND OF THE INVENTION

The passenger compartments of automobiles and trucks may retainunpleasant odors introduced into such compartment by drivers, passengersor cargo. Examples of unpleasant odors include cigarette and cigarsmoke, food odors, body odors, retained cargo odors and gas or exhaustfumes. Various air freshener devices have been designed for use invehicle passenger compartments, including devices that suspend from arear view mirror or from a sun visor.

Effective continuous action air fresheners release a sufficient amountof fragrance such that for a given enclosed space, such as a room or amotor vehicle passenger compartment, the fragrance is readilyperceptible when someone enters that space. In addition effective airfresheners deliver fragrance for an acceptable period of time, such as30 to 60 days. Moreover, such air fresheners should maintain fragrancecharacter over this time period, such that the odor impression of thefragrance when the air freshener is activated as compared to thefragrance character at the end of the functional life is relatively thesame.

Air freshening clips that join to the fins of automotive or householdventing systems are shown in the prior art. See, e.g., U.S. Pat. No.5,407,642; U.S. Pat. No. 5,527,493; U.S. Pat. No. 5,865,372; U.S. Pat.No. 6,264,887; and U.S. Pat. No. 7,687,038. Other representative hangingor suspending air freshener devices include charms or novelty deviceshung by string or stretchable elastic yarns, or air freshening devicessuspended by hooks. See, e.g., U.S. Pat. No. 7,182,270 and U.S. Pat. No.5,468,447. Scent emitting clothes hangers are also known. See, e.g.,U.S. Pat. No. 6,149,038.

Consumers may prefer portable air freshener devices that may beinstalled quickly and removed quickly from living spaces and motorvehicle passenger compartments. Devices that may be moved from onelocation to another location easily also are preferred. Consumersfurther may prefer air freshener devices with outer configurations thatmore discretely fit within a living space or motor vehicle passengercompartment.

Improvements to air freshener devices for use in conjunction with smallspaces, such as motor vehicle passenger compartments, closets andstorage areas, continue to be sought.

SUMMARY OF THE INVENTION

In a first aspect, an air freshener has a core defining a proximal end,a distal end, a length between the proximal end and distal end, and acentral axis along the length of said core of the air freshener. The airfreshener further has a fragranced polymer contacting at least a portionof the core. The fragranced polymer comprises at least one polymerincorporating one or more fragrances. The fragranced polymer may beover-molded over a portion of the core. In closed position, the airfreshener may encircle an axis that is substantially perpendicular tothe central axis. The proximal end and the distal end may be close toone another when the air freshener clip is in a closed configuration.The proximal end and the distal end are spaced apart by flexing ormoving apart when the air freshener is in an open configuration, andpreferably return to substantially their closed position after flexing.The proximal end may terminate at a face and the distal end mayterminate at a second face, and the face and second face may bejuxtaposed in substantially facing relation to one another when the airfreshener is in closed configuration. The face and second face maycontact one another or may be spaced apart from one another when the airfreshener is in closed configuration. With these configurations, the airfreshener may form a clip for attachment to a receiving structure. Inone embodiment, the face surface of the proximal end and the second facesurface of the distal end are adapted for removable connection to oneanother. In another embodiment, a strap joins the proximal end and thedistal end together. Such strap maintains the proximal end and distalend in close proximity, and is broken or cut to permit separation of theends when installing the air freshener around a receiving structure.

The core may be formed of a polymer selected from the group consistingof: polyvinylchloride, polyethylene, polyethylene terephthalate (PET),polyoxymethylene (Delrin), polyamide (nylon), low density polyethylene(LDPE), high density polyethylene (HDPE), polypropylene, ethylene vinylacetate, acrylonitrile butadiene styrene (ABS), styrene-acrylonitrile(SAN), rubber, thermoplastic elastomer (TPE), silicone, copolymersthereof, and mixtures thereof. The fragranced polymer is formed of apolymer selected from the group consisting of: polyvinylchloride,polyethylene, low density polyethylene (LDPE), high density polyethylene(HDPE), thermoplastic elastomer (TPE), polypropylene, ethylene vinylacetate, ELVAX® EVA ethylene vinyl acetate copolymer, acetate, butyrate,propionate, silicone, copolymers thereof, and mixtures thereof. The corepolymer and the fragranced polymer may be selected such that the polymermaterials chemically bind or adhere to one another. Alternatively, thecore polymer and the fragranced polymer may be selected such that thepolymer materials do not bind to one another, to allow the fragrancedpolymer to slip or move in relation to the core polymer at the interfacebetween the core polymer and the fragranced polymer.

In some embodiments, both the core polymer and the fragranced polymerincorporate or contain one or more fragrance oils. Fragrance oils may benatural or synthetic, or combinations of such.

In another embodiment of the invention, an air freshener comprises acore defining a proximal end, a distal end, a length between theproximal end and distal end, and a central axis along the length of saidcore of the air freshener, and a sleeve contacting at least a portion ofthe core, where the sleeve comprises at least one polymer incorporatingone or more fragrances. The air freshener surrounds or encircles an axisthat is substantially perpendicular to the central axis. The centralaxis may be curved along at least a portion thereof. The sleeve may beover-molded over a portion of the core.

The core may have an upstanding inner wall beginning at or near theproximal end and terminating at or near the distal end of the airfreshener. The core also may define a first trough between a first sideof the upstanding inner wall and an inside exterior wall. The core alsomay have an I-beam strengthening section spaced apart from theupstanding inner wall and having an upper I-beam wall generallyfollowing the contour of said upstanding inner wall. The upstandinginner wall and I-beam strengthening section of the core may define asecond trough therebetween. The I-beam strengthening section mayterminate at one end defining a hole between the I-beam strengtheningsection and the distal end of the air freshener. The I-beamstrengthening section may terminate at its other end defining a secondhole between the I-beam strengthening section and the proximal end ofthe air freshener. The core may further define a third trough betweenthe inside exterior wall and the I-beam strengthening section. TheI-beam strengthening section may define an apex and a reinforcement maybe provided at such apex, to stabilize or reinforce the clip forrepeated bending and flexing. Preferably, the sleeve is disposed overand around the I-beam strengthening section, and through the first holeand second hole of the I-beam strengthening section. The sleeve materialmay also be disposed in the second trough and the third trough, wherethe sleeve abuts one side of the upstanding inner wall and one side ofthe inside exterior wall of the core.

In some embodiments, the face surface of the proximal end and the secondface surface of the distal end abut one another. The face surface of theproximal end and the second face surface of the distal end also may beadapted for removable connection to one another. For example, a maleconnector may extend from at least one of the face surface of theproximal end and the second face surface of the distal end, and a femaleconnector may be defined by the other of the at least one of the facesurface of the proximal end and the second face surface of the distalend. The male connector may be received within the female connector forlinking engagement to close the air freshener around a receivingstructure. The male connector may be released from the female connectorto permit the proximal end and distal end to be separated apart, andthereby to release the air freshener clip from a receiving structure. Asanother example, the face surface of the proximal end may define acavity or recess to receive the distal end of the air freshener. In suchconfiguration, distal end of the air freshener may have an outerdiameter that is smaller than the outer diameter of the proximal end ofthe air freshener.

In yet another embodiment, an air freshener may have a core defining aproximal end, a distal end and a central axis of the air freshener,where the air freshener encircles an axis that is substantiallyperpendicular to the central axis. The core may have an upstanding innerwall beginning at or near the proximal end and terminating at or nearthe distal end of the air freshener. In this embodiment, the corefurther may have an interior section defining a plurality of ribbedchannels between a first side of the upstanding inner wall and an insideexterior wall. A sleeve may contact at least a portion of the core, saidsleeve comprising at least one polymer incorporating one or morefragrances. The sleeve may be over-molded over the core. The proximalend and the distal end of the air freshener are separable from oneanother and movable (or flexed) away from one another, either in adirection generally parallel to said axis that is substantiallyperpendicular to the central axis, or in a direction along the centralaxis, or in a combination of such directions. Preferably, the core isformed of a polymer material without fragrance oil. When viewed in crosssection, the core preferably comprises more than 180° of the exteriorperiphery of the air freshener. This embodiment may include the I-beamstrengthening section, and the sleeve may be disposed over and aroundsuch I-beam strengthening section. The I-beam strengthening section mayinclude a reinforcement at the apex of the air freshener.

The air freshener of still another embodiment of the invention mayindicate the level of fragrance dissipation. In this embodiment, theouter portion or sleeve overmolded over the core is not molded aroundstraps or through holes provided at or near the distal and proximal endsof the air freshener. After passage of a predetermined time, with thedissipation of the fragrance oil from the polymer of the outer portionor sleeve, the sleeve length shrinks to a length that is less than itsinitial sleeve length (determined immediately after the sleeve isinstalled or over-molded onto the core). This shrinkage will be observedby an ordinary observer because greater portions of the core at thedistal end and at the proximal end of the air freshener previouslycovered by the outer portion or sleeve will be exposed to view.

One possible method for making an air freshener includes the steps of:(1) injection molding a first shot of at least one polymer material toform a core, said core defining a proximal end, a distal end and acentral axis of the air freshener; and (2) injection molding a secondshot of at least one polymer material incorporating one or morefragrance materials onto or into or over at least a portion of the core.The second shot may form a sleeve over at least a portion of the core.Preferably, injection molding is conducted in a valve gated hot runnersystem. Preferably, the sleeve is disposed over and around an I-beamstrengthening section formed in the core. In a particularly preferredembodiment, the second shot of polymer material is stretched about thecore during injection molding.

The method for making an air freshener is particularly suitable formaking an air freshener that has a core with an upstanding inner wallbeginning at or near the proximal end and terminating at or near thedistal end of the air freshener. The core further may define a firsttrough between a first side of the upstanding inner wall and an insideexterior wall. The I-beam strengthening section may be spaced apart fromthe upstanding inner wall and have an upper I-beam wall generallyfollowing the contour of said upstanding inner wall. The upstandinginner wall and I-beam strengthening section may define a second troughtherebetween. Preferably, the I-beam strengthening section terminates atone end defining a hole between the I-beam strengthening section and thedistal end of the air freshener, and terminates at its other enddefining a second hole between the I-beam strengthening section and theproximal end of the air freshener. The core still further may define athird trough between the inside exterior wall and the I-beamstrengthening section. With this air freshener structure, it is possiblefor the second shot of polymer material to flow into and fill the firsthole and second hole of the I-beam strengthening section. This helpsstabilize the second shot of polymer material onto and in connectionwith the core, and lessens shrinkage where shrinkage is not desired.

A method of emitting fragrance into a small space, such as an automobilepassenger compartment or a closet or other small space, comprisesinstalling an air freshener clip according to the invention onto oraround a receiving structure. Possible receiving structures include, butare not limited to, rear view mirrors, rear view mirror supports ornecks, motor vehicle door handles, curtain rods, closet rods, hangers,shelving, shelving support posts, drawer pulls, drawer handles, beltloops, shoes, shoe racks, hampers, gym bags, lockers, shower doors,towel racks, trash cans, pipes, wires, tables and carts.

DESCRIPTION OF THE FIGURES

Numerous other objects, features and advantages of the invention shallbecome apparent upon reading the following detailed description taken inconjunction with the accompanying drawings, in which:

FIG. 1 is a right rear perspective view of an air freshener;

FIG. 2 is a rear plan view of the air freshener of FIG. 1;

FIG. 3 is a front plan view of the air freshener of FIG. 1;

FIG. 4 is a bottom view of the air freshener of FIG. 1;

FIG. 5 is a top view of the air freshener of FIG. 1;

FIG. 6 is a right side view of the air freshener of FIG. 1;

FIG. 7 is a rear plan view of a core of an air freshener;

FIG. 7A is a cross-sectional view of the core taken along line 7A-7A inFIG. 7;

FIG. 8 is a front plan view of the core of FIG. 7;

FIG. 9 is a right rear perspective view of an alternative air freshener;

FIG. 10 is a rear plan view of the air freshener of FIG. 9;

FIG. 11 is a front plan view of the air freshener of FIG. 9;

FIG. 12 is a bottom view of the air freshener of FIG. 9;

FIG. 13 is a top view of the air freshener of FIG. 9;

FIG. 14 is a right side view of the air freshener of FIG. 9;

FIG. 15 is a schematic view in cross section of a valve gated hot runnersystem injection mold;

FIG. 16 is a bottom view of an air freshener with a strap and with maleand female connectors;

FIG. 17 is a right rear perspective view of the air freshener of FIG. 16with flexed apart distal end and proximal end;

FIG. 18 is a bottom view of an alternative air freshener in a ringconfiguration;

FIG. 19 is a front plan view of the air freshener of FIG. 18;

FIG. 20 is a bottom view of yet another alternative air freshener in aring configuration;

FIG. 21 is a front plan view of the air freshener of FIG. 20; and

FIG. 22 is a right front perspective view of an air freshener installedon a rear view mirror support or neck.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

With reference to the drawings in which like numerals designate similarelements, a first embodiment of an air freshener 10 is shown in FIGS.1-6. The air freshener 10 is comprised of a central core 12 with anouter portion or sleeve 50. The core 12 is shown more particularly inFIGS. 7 and 8. The air freshener 10 has a proximal end 14 and a distalend 16, and is looped or curved or rounded about an axis 40 to form around or teardrop shape. The air freshener 10 preferably has at least aportion that is curved, such as shown in FIGS. 1-6. Alternatively, theair freshener 10 may encircle or surround the axis 40 with otherpolymeric or geometric shape.

In a preferred embodiment, the proximal end 14 and distal end 16 of theair freshener 10 have generally planar face surfaces 36, 38 that arejuxtaposed in slightly spaced apart, facing relationship. However, allor some portions of the planar faces 36, 38 of each of the proximal end14 and distal end 16 may abut or contact one another when the airfreshener 10 is in its closed configuration. The air freshener 10 mayform a clip, such that in its closed configuration it can be clipped toa receiving structure or mounting structure.

Referring to FIGS. 7 and 8, the core 12 of this embodiment has anupstanding inner wall 18 that extends from the proximal end 14 to thedistal end 16 and generally follows the curved or shaped contour of theair freshener 10. Mold gating locations 46 are shown adjacent theupstanding inner wall 18. The upstanding inner wall 18 is spaced apartfrom an inside exterior wall 20 defining a trough 21 therebetween. Theinner trough walls formed by the upstanding inner wall 18 and insideexterior wall 20 may be generally straight, or may be angled.Preferably, the exterior of the inside exterior wall 20 is convexlycurved.

The upstanding inner wall 18 of the air freshener 10 of the embodimentof FIGS. 7 and 8 is spaced apart from an I-beam strength section 22defining a second trough 24 therebetween. The inner trough walls of thesecond trough formed by the upstanding inner wall 18 and the I-beamstrength section 22 may be generally straight, as shown in FIG. 7, ormay be angled. As shown in FIG. 7, the trough 24 has a generally planarlower trough surface. The I-beam strength section 22 generally followsthe curved or shaped contour of the air freshener 10 and the upstandinginner wall 18. The I-beam strength section 22 has an outer wall thatterminates near the distal end of the air freshener. Strap 26 joins theend of the I-beam strength section 22 to the proximal end 14 of the airfreshener 10. Second strap 28 joins the opposite end of the I-beamstrength section 22 to the distal end 16 of the air freshener 10.Between the strap 26 and the upstanding inner wall 18 a hole 30 isformed. Between the second strap 28 and the upstanding inner wall 18 ahole 32 is formed. The holes 30, 32 may be oval slots, or other desiredhole configuration.

The air freshener 10 defines a central axis along its length. Where theair freshener 10 is curved, such central axis is curved, and the airfreshener 10 may form a curved shape, such as in the configuration of atear drop as shown in FIGS. 1-6.

The I-beam strength section 22 of the core 12 may have a reinforcement44 at the apex 42 of the curved I-beam strength section 22. As shown inFIGS. 7 and 8, the reinforcement 44 comprises an added amount ofmaterial thickness in the “I” portion of the I-beam strength section,thus reinforcing the core 12 to accommodate bending stresses when theproximal end 14 and distal end 16 of the air freshener 10 are flexedapart or moved away from one another to open the air freshener.

In this embodiment, an outer portion or sleeve 50 of fragranced polymeror fragranced polymer mixture is molded over (or over-molded over) aportion of the core 12. As shown in FIGS. 1 and 2, the sleeve 50 abutsone side of the upstanding inner wall 18, and fills the second trough24. The sleeve material covers the I-beam strength section 22 and fillsthe third trough 34. Preferably, the sleeve material is not molded intothe first trough 21. The sleeve 50 preferably is molded to have aconvexly curved outer surface. Upon molding, the sleeve material coversthe straps 26, 28 that join the ends of the I-beam strength section 22to the proximal and distal ends of the air freshener, and the sleevematerial flows into the holes 30, 32, thus securing the sleeve materialto the proximal and distal ends of the air freshener 10 and to theI-beam strength section.

Alternatively, the I-beam strength section 22 may terminate at each endwithout having straps 26 and without forming the holes 30, 32. The outerportion or sleeve material (fragranced polymer or polymer mixture) maybe over-molded over the core 12, in the same manner, but without lockingaround straps or into holes. In such embodiment, the sleeve materialfunctions also to indicate when fragrance has depleted from the airfreshener 10. The sleeve material shrinks as fragrance dissipates fromthe sleeve material polymer. Such shrinkage will be evident first at theproximal and distal ends of the air freshener, where the sleeve materialmay begin to pull away from such ends. In such embodiment, it ispreferable that fragranced polymer outer portion 50 comprises a polymeror mixture of polymers different from that comprising the core 12, andthe polymer materials do not chemically bind to one another and are nototherwise adhered to one another to permit the desired shrinkage orslippage.

The core 12 may be molded from a polymer containing at least one resinselected from the group consisting of: polyvinylchlorides (PVC),polyethylenes (PE), polyethylene terephthalates (PET), polyoxymethylene(Delrin), polyamides (nylon), low density polyethylene (LDPE), highdensity polyethylene (HDPE), polypropylenes, ethylene vinyl acetate,acrylonitrile butadiene styrene (ABS), and styrene-acrylonitrile (SAN),rubber, thermoplastic elastomer (TPE), silicone, copolymers thereof andmixtures thereof. The resin composition may be mixed, blended orcompounded together optionally with additives known in the art and withone or more fragrance materials to form an injection-moldable mixturebefore injection molding. A preferred amount of resin to form the coreis from 2 g to 100 g, more preferably 3 g to 20 g.

The outer portion or sleeve 50 may be a different polymer resin fromthat selected for the body or core 12. The sleeve 50 may be over moldedover the core 12 in a multiple shot molding process. In a multiple shotmolding process, the core 12 is formed in a first molding step and thesleeve 50 is formed over the core 12 in a second or subsequent moldingstep. The core 12 and sleeve 50 may be molded by injection molding,particularly by valve gated hot runner injection molding as described inmore detail below.

The fragranced polymer or outer portion or sleeve 50 may be molded fromat least one resin selected from the group consisting of:polyvinylchlorides (PVC), polyethylenes (PE), high density polyethylenes(HDPE), low density polyethylene (LDPE), polyvinylchoride (PVC),polypropylenes, ethylene vinyl acetate copolymers (EVA), such as ELVAX®EVA ethylene vinyl acetate copolymer, thermoplastic elastomers (TPE),polypropylenes, acetate, butyrate and propionate, silicone, copolymersthereof, and mixtures thereof. The resin composition may be mixed,blended or compounded together with one or more fragrance materials andoptionally with other additives known to those in the art to form aninjection-moldable mixture before injection molding. A preferred amountof resin to form the fragranced polymer or outer portion or sleeve isfrom 2 g to 100 g, more preferably 3 to 20 g.

A “fragrance material” may be any material that has a smell or odor.Most conventional fragrance materials are highly volatile essentialoils. Even those which are less volatile contain highly volatile “topnote” fractions which preferably are retained in the composition duringprocessing to obtain desired fragrance power and olfactory impact by theresultant molded article. A fragrance material or a combination offragrance materials that is compatible with the selected resincomposition is preferred. The fragrance material may be a syntheticallyformed material or may be a naturally derived oil such as, but notlimited to, the oil of Bergamot, Bitter Orange, Caraway, Cedar Leaf,Cedar Wood, Champacc, Cinnamon, Frankincense, Geranium, Lavender,Mimosa, Orange, Orignaum, Patchouli, Rosewood, Sandalwood, Vanilla,Violet, White Cedar, Ylang Ylang, Limonene, menthol, eucalyptus, camphoror the like. The particular essential oil or combination of oils to beused depends upon the particular fragrance desired for emission by theproduct formed.

Alternatively or additionally, the fragrance material may comprise oract as a volatile insecticide and/or insecticidal synergist orattractant or repellant, such as pyrethrum, octenol, linalool, mint oil,or a bacteriostat or pheromone. Alternatively or additionally, thefragrance material may comprise or act as a vaporous remedy forrespiratory conditions, such as a vapor to relieve symptoms of colds andallergies.

Available fragrance materials are catalogued and described in referencesand databases known to persons skilled in the art. For example, adatabase is maintained by the Research Institute for Fragrance Materialsat www.rifm.org. Fragrance material suppliers include TakasagoInternational Corp. (Rockleigh, N.J.) and Symrise (Teterboro, N.J.).Exemplary synthetic fragrance materials are described in U.S. Pat. Nos.4,411,829; 4,314,915 and 4,434,306. Preferred amounts of fragranceloading in resin are from about 5% to about 45% by weight of the resin.

Colorants (such as pigments known for use with thermoplastic andthermoset resins) may be incorporated into the polymers to improveaesthetics. Examples of suitable colorants also include any water-basedcolorant such as food coloring, and Reactint polymeric colorant fromMilliken Chemical (Spartanburg, S.C.).

Other additives may be incorporated into the polymers as desired,including one or more plasticizers, one or more stabilizers, andoptionally one or more lubricants.

Preferably, the outer portion or sleeve 50 comprises a fragrancedpolymer that is loaded with a suitable amount of fragrance oil(s). Morefrequently, the polymer(s) forming the core 12 will not includefragrance oil(s). When the air freshener 10 is installed over aretaining structure, the core will contact the retaining structuresurfaces. Preferably, when viewed in cross section, the core 12comprises more than 180° of the exterior periphery of the air freshener10. As such, only the core will contact the retaining structuresurfaces. Then, such core 12 without fragrance oil(s) will not leach ordissipate fragrance oils onto the retaining structure surfaces. In someembodiments, however, the core 12 also may comprise a fragranced polymerthat is loaded with a suitable amount of the same or different fragranceoil(s).

FIG. 15 shows a representative injection mold system 80 having a valvegated hot runner system. In FIG. 15, a fixed mold 82 and a movable mold84 are placed in contact with each other at a mold parting surface so asto define a cavity C, a cylinder chamber 86 is formed in the fixed mold82. A first hot runner block 88 and a second hot runner block 90 arefitted in the fixed mold 82. The first hot runner block 88 and thesecond hot runner block 90 are spaced a predetermined distance from eachother by a heat-insulating member 92 in overlapping relation to eachother. The first hot runner block 88 has a first sprue 94, a first hotrunner 96, a seat portion 98, and a gate G. The second hot runner block90 has a second sprue 100 and a second hot runner 102. A piston 104 ismounted within the cylinder chamber 86 of the fixed mold 82. A valvemember 106 connected to this piston extends through the second hotrunner block 90 and fits in the first hot runner block 88. A resinpassage 108 is formed in the valve member 106. One end of the resinpassage 108 communicates with the second hot runner 102 and the otherend thereof communicates with the gate G.

When the distal end of the valve member 106 is pressed against the seatportion 98 of the first hot runner block 88 as shown in FIG. 15, thevalve member is disposed in a first hot runner-closing position, thecommunication between the first hot runner 96 and the cavity C isinterrupted. When the valve member 106 is spaced apart from the seatposition, the first hot runner 96 communicates with the cavity C.Regardless of the position of the valve member 106, the second sprue 100always communicates with the cavity C via the second hot runner 102 andthe resin passage 108. A heat-insulating member 110 is provided betweenthe fixed mold 82 and the first hot runner block 88, and aheat-insulating member 112 is provided between the fixed mold and thesecond hot runner block 90. The heat-insulating members 92, 110, and 112prevent heat transfer between the first and second hot runner blocks 88and 90, between the fixed mold 82 and the first hot runner block 88, andbetween the fixed mold 82 and the second hot runner block 90,respectively.

The two molds 82 and 84 are closed and clamped together by a moldclamping device (not shown). Air pressure is supplied to a lower chamberof the cylinder chamber 86 of the fixed mold 82 so as to move the valvemember 106 to the first hot runner-opening position which is somewhatabove the illustrated position of the valve member. By doing so, thefirst hot runner 96 communicates with the cavity C. A first polymer shot114 is then injected from the first sprue 94. The first polymer shotresin 114 passes through the first sprue 94, the first hot runner 96,and the gate G, and flows into the cavity C. The injection molding iscarried out at a temperature above the Vicat softening temperature ofthe resin, and generally above 100° C., and under pressures commonlyused in injection molding.

When a predetermined amount of resin 114 has been injected, air pressureis supplied to an upper chamber of the cylinder chamber 86 so as to movethe valve member 106 to the first hot runner-closing position. By doingso, the injection of the first polymer shot resin 114 is terminated.Slightly before, or simultaneously with, the end of the injection of thefirst polymer shot resin 114, a second shot polymer resin 120 isinjected from the second sprue 100. The second shot polymer resin 120passes through the second sprue 100, the second hot runner 102, and thegate C, and finally flows into the cavity C. After a predeterminedamount of the second shot resin 120 has been injected, the process isfinished. Accordingly, a molded product 130 having a core of secondpolymer and a sleeve of first polymer can be produced. Since the secondshot polymer resin 120 can be injected successively after the injectionof the first shot polymer resin 114, or vice versa, the resin flow neverstops, and therefore, hesitation marks are not likely to develop on thesurface of the molded product.

The I-beam strengthening section 22 of the core 12 of the preferredembodiment air freshener 10 allows the second shot forming the outerportion or sleeve 50 to slide between the two attached ends to reduceinternal stresses and reduce total part warpage.

The gating locations 46 on the first shot polymer resin forming the coreand the gating location 48 on the second shot polymer resin forming thesleeve are intended to use molecular orientation to help reduce totalpart warpage by better dimensional control as the air freshener 10 isinjection molded.

Referring next to FIGS. 9 to 14, an alternate embodiment of an airfreshener 60 is shown. In this alternate embodiment, a core 62 stillincludes an upstanding inner wall 18 separated from an I-beam strengthsection 22 (not shown in FIGS. 9 to 14) by a second trough 24. However,rather than the inside exterior wall and first trough as shown in theembodiment in FIG. 1, this second embodiment 60 includes an innersection 68 between the upstanding inner wall 18 and the third trough 34.The inner section 68 comprises the same polymer material of theremainder of the core. A series of slots 64 are formed in or cut fromthe inner section 68 forming an array of slots 64 separated by ribs 66.The slots 64 are disposed in a direction generally perpendicular to thecenter axis of the core 62. The slots 64 and ribs 66 enhance bending ortwisting of the air freshener 60 when opening the air freshener bymoving the proximal end 14 and distal end 16 away from one another, suchas in direction(s) generally parallel to the axis 40 of the airfreshener 60 or generally along the central axis of the air freshener.

In the preferred embodiments, the air freshener 10, 60 of the inventionmay generally have a thickness of about 1 cm, and a length of about 8 to10 cm (as measured from the ends to the apex of the curved or roundedclip). The I-beam strength section has a length traversing the length ofthe core, and generally about 16 to 20 cm. The width of the “I” portionof the I-beam strength section is about 3 to 5 mm. The upstanding innerwall has a thickness of about 1 to 2 mm. The depth of the first troughis about 5 to 8 mm. The depth of the second trough is about 4 to 6 mm.The depth of the third trough is about 4 to 6 mm. The length of thestraps is about 1 to 2 mm. The holes defined between the ends and thestraps and the I-beam strength section have lengths of about 5 mm andheights of about 1 to 2 mm.

FIGS. 16 and 17 show an air freshener 10A comparable to that shown inFIGS. 1-8 that includes additional features at or near the proximal end14 and distal end 16. In FIG. 16, a strap 58 links the proximal end 14and the distal end 16 together. The strap 58 may be formed from the samepolymeric material as the core 12 when the core is molded. The strap 58helps maintain alignment during molding and curing of the air freshener.For example, the strap 58 helps to resist twisting, bending and/orseparating of the proximal end and distal end. The strap 58 may have athin profile such that a user or consumer may snap, break or cut thestrap before installing the air freshener 10A onto a mounting structureor receiving structure. Once the strap 58 is broken, the proximal end 14and distal end 16 may be separated from one another or moved away fromone another.

As shown in FIG. 17, the proximal end 14 and distal end 16 may be flexedaway from one another, such as in the direction of arrow 70. By twistingor flexing or pulling apart the ends 14, 16 of the air freshener 10A,60, the air freshener may be opened to permit it to be installed over oraround mounting structures or receiving structures. Representativemounting structures or receiving structures include, but are not limitedto, the supporting post or neck of a rear view mirror of a motorvehicle, or a door handle, or a curtain rod, or a furniture or cabinethandle or drawer pull, or a clothes rack or closet rod, or a shoe, or ashoe rack, or a laundry hamper, or a gym bag, or a locker, or a showerdoor, or a trash can, or a pipe or wire, or a table or a cart. Uponreleasing the twisting, flexing or pulling force, the ends 14, 16preferably return substantially to their unflexed or closedconfiguration. In such manner, the air freshener 10A readily may beinstalled over or around a mounting or receiving structure.

Twisting, flexing or pulling apart of the ends 14, 16 of the airfreshener 10A, 60 is enhanced where the core and the fragranced polymerare formed of different polymers that do not chemically bind or adhereto one another. Some slippage between the polymers of the core and thefragranced polymer permits optimum bending to an open configuration andrecovery or return to a closed configuration or substantially closedconfiguration.

In one embodiment shown in FIGS. 16 and 17, the face surfaces 36, 38 ofthe proximal end 14 and distal end 16 of the air freshener 10A may beconnected together when the air freshened 10A is installed or engaged toa mounting structure. In such embodiment, for example, a male connector54 may project from the face surface of either the proximal end or thedistal end, and a female receiving channel or orifice 56 may be providedin the face surface of the other end. The male connector 54 may be heldwithin the female receiving channel or orifice 56 when the connector isclosed, and may be removably slid or ejected from the female receivingchannel or orifice 56 to open the air freshener 10A.

In another embodiment of according to the invention shown in FIGS. 18and 19, an air freshener 200 is shown in a closed configuration, forminga circular ring. A first or proximal end 202 of the air freshener 200has a first outer diameter and defines in its end face an open cavity orrecess 204 therein. A second or distal end 206 of the air freshener 200has an outer diameter smaller than the first outer diameter. The secondor distal end 206 mates within the cavity or recess 204 of the first orproximal end 202. To open the air freshener 200, the ends 202, 206 arepulled apart or pulled away from one another to create separation oropen space between them.

In still another embodiment according to the invention shown in FIGS. 20and 21, an air freshener 300 forms a circular ring in closedconfiguration. A first or proximal end 302 of the air freshener 300defines a recess or cavity 304. A second or distal end 306 of the airfreshener 300 defines a mating extension 310 in the form of a dovetail.Such mating extension 310 releaseably slides for connection into therecess or cavity 304. To open the air freshener 300, the ends 302, 306are slid in direction of arrows 312 a, 312 b to release the matingextension 310 from the mating recess or cavity 304. Once released, theends 302, 306 may be pulled apart or pulled away from one another tocreate separation or open space between them.

Referring to FIG. 22, an air freshener 10 according to the invention isinstalled around a supporting post 72 of a rear view mirror 74 of amotor vehicle. The invention has been illustrated with particularreference to suspending or hanging the air freshener 10 to a rear viewmirror of a motor vehicle. The air freshener 10 may be useful inalternative environments of use, such as attached or clipped to curtainrods in closets or cabinets, or to motor vehicle door handles, curtainrods, closet rods, hangers, shelving, shelving support posts, drawerpulls, drawer handles, belt loops, shoes, shoe racks, hampers, gym bags,lockers, shower doors, towel racks, trash cans, pipes, wires, tables,and carts, and is not intended to be limited to the environment of useillustrated here.

Alternatively, an air freshener according to the invention may beinstalled on a belt or on a belt loop or other clothing item and worn asa personal air freshening device. Such embodiment has particular appealwhere the fragrance material comprises a volatile insecticide, or wherethe fragrance material comprises a cold or allergy vapor remedy.

Example

An example air freshener is formed as a clip of the embodiment of FIGS.1-8. The core is injection molded of about 6 g of a polypropylenecopolymer. The sleeve is injection molded over the core. The sleevecomprises 5.75 g of a polyethylene copolymer, with 30 percent by weightof vanilla fragrance oil and 3 weight percent color.

Air fresheners may be tested for fragrance character and fragrancestrength using a fragrance panel test known in the fragrance industry. Asample air freshener product is suspended in a room with dimensions of25 feet by 16 feet by 9 feet. A panel of at least four persons ranks thestrength and character of the aroma emitted by the various air freshenerproducts on a scale of 0 to 5, with 5 being the strongest and 5 beingthe closest in character to the fragrance oil. The fragrance power andfragrance character are observed over a four-week period. The fragrancepower values are averaged, and the fragrance character values areaveraged. Products that receive average rankings of 3 and above for theentire testing period are satisfactory for use as continuous action roomair fresheners.

Air fresheners may be tested for suitability and durability for use asair fresheners. For example, the air fresheners may be frozen for atleast 12 hours and thawed over a repeated number of cycles (such as 3cycles) to determine whether fragrance material exudes from the polymerupon thawing. Air fresheners may be heated to an elevated temperature ofat least 120° F. and held for 4 weeks at such temperature, in packagingand outside of packaging, to determine whether fragrance exudes andwhether fragrance strength and fragrance character degrade. Airfresheners may be exposed to ultraviolet light testing for at least 4weeks to determine effect of light on product color and fragrancecharacter.

While preferred embodiments of the invention have been described andillustrated here, various changes, substitutions and modifications tothe described embodiments will become apparent to those of ordinaryskill in the art without thereby departing from the scope and spirit ofthe invention.

What is claimed is:
 1. An air freshener, comprising: a core defining aproximal end, a distal end, a length between the proximal end and distalend, and a central axis along the length of said core of the airfreshener, wherein the central axis is curved along at least a portionthereof; and a fragranced polymer sleeve contacting at least a portionof the core, said fragranced polymer sleeve comprising at least onepolymer incorporating one or more fragrance materials, wherein saidproximal end and said distal end are close to one another when the airfreshener is in a closed configuration, and are spaced apart by flexingor moving away when the air freshener is in an open configuration;wherein the air freshener encircles an axis that is substantiallyperpendicular to the central axis; wherein the proximal end terminatesat a face surface, and the distal end terminates at a second facesurface; and wherein the face surface of the proximal end and the secondface surface of the distal end are juxtaposed in substantially facingrelation to one another.
 2. The air freshener of claim 1, wherein theface surface of the proximal end and the second face surface of thedistal end contact one another when the air freshener is in closedconfiguration.
 3. The air freshener of claim 1, wherein the face surfaceof the proximal end and the second face surface of the distal end areadapted for removable connection to one another.
 4. The air freshener ofclaim 3, wherein the distal end defines a female receiving portion and amale connector extends from the proximal end.
 5. The air freshener ofclaim 1, further comprising a strap joining the proximal end and thedistal end together.
 6. The air freshener of claim 1, wherein theproximal end and the distal end of the air freshener are separable fromone another and movable in directions generally parallel to said axis orin directions along said central axis.
 7. The air freshener of claim 1,wherein, when viewed in cross section, the core comprises more than 180°of the exterior periphery of the air freshener.
 8. The air freshener ofclaim 1, wherein the fragranced polymer is over-molded over at least aportion of the core.
 9. The air freshener of claim 1, wherein the coreis formed of a first polymer or polymer mixture and the fragrancedpolymer is formed of a second polymer or second polymer mixturedifferent from the first polymer or polymer mixture.
 10. The airfreshener of claim 1, wherein the core is formed of a polymer selectedfrom the group consisting of polyvinylchloride, polyethylene,polyethylene terephthalate (PET), polyoxymethylene (Delrin), polyimide(nylon), low density polyethylene (LDPE), high density polyethylene(HDPE), polypropylene, ethylene vinyl acetate, acrylonitrile butadienestyrene (ABS), styrene-acrylonitrile (SAN), rubber, thermoplasticelastomer (TPE), silicone, copolymers thereof, and mixtures thereof. 11.The air freshener of claim 1, wherein the fragranced polymer is formedof a polymer selected from the group consisting of: polyvinylchloride,polyethylene, low density polyethylene (LOPE), high density polyethylene(HOPE), thermoplastic elastomer (TPE), polypropylene, ethylene vinylacetate, ELVAX® EVA ethylene vinyl acetate copolymer, acetate, butyrate,propionate, silicone, copolymers thereof, and mixtures thereof.
 12. Theair freshener of claim 1, wherein the core has an upstanding inner wallbeginning at or near the proximal end and terminating at or near thedistal end.
 13. The air freshener of claim 12, wherein the core has aninterior section defining a plurality of ribbed channels disposed in aspaced apart relation in an array between a first side of the upstandinginner wall and an inside exterior wall.
 14. The air freshener of claim12, wherein the core further comprises an I-beam strengthening sectionspaced apart from the upstanding inner wall and having an upper I-beamwall generally following the contour of said upstanding inner wall, theupstanding inner wall and I-beam strengthening section defining a troughtherebetween, where the I-beam strengthening section terminates at oneend defining a hole between the strengthening section and the distal endof the air freshener and where the I-beam strengthening sectionterminates at its other end defining a second hole between the I-beamstrengthening section and the proximal end of the air freshener.
 15. Theair freshener of claim 14, wherein the I-beam strengthening sectiondefines an apex and a reinforcement is provided at the apex.
 16. The airfreshener of claim 14, wherein the fragrance polymer is disposed overand around the I-beam strengthening section, and through the first holeand the second hole of the I-beam strengthening section.
 17. The airfreshener of claim 12, wherein the inside exterior wall defines aconvexly curved outer surface of the air freshener.
 18. The airfreshener of claim 1, wherein the fragranced polymer is formed of amaterial that does not bind to the core.
 19. The air freshener of claim1, wherein the fragranced polymer is formed of a material that binds tothe core.
 20. The air freshener of claim 8, wherein the fragrancedpolymer has a first length upon initial molding, and after passage of apredetermined time after initial molding, the fragranced polymer lengthshrinks to a length less than its first length.
 21. The air freshener ofclaim 1, wherein the fragranced polymer forms a convexly curved outersleeve of the air freshener.
 22. The air freshener of claim 1, whereinthe proximal end and distal end return substantially to the closedconfiguration after being separated to an open configuration.
 23. Amethod of emitting fragrance into a small space, comprising installingthe air freshener of claim 1 onto or around a receiving structure. 24.The method of claim 23, wherein the receiving structure is selected fromthe group consisting of: rear view mirror, rear view mirror support orneck, motor vehicle door handle, curtain rod, closet rod, hanger,shelving, shelving support post, drawer pull, drawer handle, belt loop,shoe, shoe rack, hamper, gym bag, locker, shower door, towel rack, trashcan, pipe, wire, table, and cart.
 25. The method of claim 23, whereinthe receiving structure is a clothing item or a part of a clothing item.26. An air freshener, comprising: a core defining a proximal end with aface surface, a distal end with a second face surface, a length betweenthe proximal end and distal end, and a central axis along the length ofsaid core of the air freshener; and a fragranced polymer sleevecontacting at least a portion of the core, said fragranced polymersleeve comprising at least one polymer incorporating one or morefragrance materials; wherein the air freshener surrounds an axis that issubstantially perpendicular to the central axis, and wherein the facesurface of the proximal end and the second face surface of the distalend abut one another when the air freshener is in a closed position. 27.The air freshener of claim 26, wherein the central axis is curved alongat least a portion thereof.
 28. The air freshener of claim 26, whereinthe fragranced polymer forms a sleeve that is disposed over at least aportion of the core.
 29. The air freshener of claim 28, wherein thesleeve is over-molded over at least a portion of the core.
 30. The airfreshener of claim 29, wherein the fragranced polymer has a first lengthupon initial molding, and after passage of a predetermined time afterinitial molding, the fragranced polymer length shrinks to a length lessthan its first length.
 31. The air freshener of claim 26, furthercomprising a strap joining the proximal end and the distal end together.32. The air freshener of claim 26, wherein the face surface of theproximal end and the second face surface of the distal end are adaptedfor removable connection to one another.
 33. The air freshener of claim32, wherein a male connector extends from at least one of the facesurface of the proximal end and the second face surface of the distalend, and a female connector is defined by the other of the at least oneof the face surface of the proximal end and the second face surface ofthe distal end.
 34. The air freshener of claim 26, wherein the proximalend and the distal end of the air freshener are separable from oneanother and movable in directions generally parallel to said axis or indirections generally parallel to said central axis.
 35. The airfreshener of claim 26, wherein the core has an upstanding inner wallbeginning at or near the proximal end and terminating at or near thedistal end.
 36. The air freshener of claim 35, wherein the core has aninterior section defining a plurality of ribbed channels that aredisposed in a spaced apart relation in an array between a first side ofthe upstanding inner wall and an inside exterior wall.
 37. The airfreshener of claim 35, wherein the core further comprises an I-beamstrengthening section spaced apart from the upstanding inner wall andhaving an upper I-beam wall generally following the contour of saidupstanding inner wall, the upstanding inner wall and I-beamstrengthening section defining a trough therebetween, where the I-beamstrengthening section terminates at one end defining a hole between theI-beam strengthening section and the distal end of the air freshener andwhere the I-beam strengthening section terminates at its other enddefining a second hole between the I-beam strengthening section and theproximal end of the air freshener.
 38. The air freshener of claim 37,wherein the I-beam strengthening section defines an apex and areinforcement is provided at the apex.
 39. The air freshener of claim37, wherein the fragrance polymer is disposed over and around the I-beamstrengthening section, and through the first hole and the second hole ofthe I-beam strengthening section.
 40. The air freshener of claim 35,wherein the inside exterior wall defines a convexly curved outer surfaceof the air freshener.
 41. The air freshener of claim 26, wherein thefragranced polymer forms a convexly curved outer sleeve of the airfreshener.
 42. The air freshener of claim 26, wherein the core comprisesat least one polymer incorporating one or more fragrances.
 43. A methodof emitting fragrance into a small space, comprising installing the airfreshener of claim 26 onto or around a receiving structure.
 44. Themethod of claim 43, wherein the receiving structure is selected from thegroup consisting of: rear view mirror, rear view mirror support or neck,motor vehicle door handle, curtain rod, closet rod, hanger, shelving,shelving support post, drawer pull, drawer handle, belt loop, shoe, shoerack, hamper, gym bag, locker, shower door, towel rack, trash can, pipe,wire, table, and cart.
 45. The method of claim 43, wherein the receivingstructure is a clothing item or a part of a clothing item.